100 router match iterations

readme.md

These changes would allow you to ensure that useCache = false for the loadModules, loadDb, and saveCache calls.

Now, I have no idea how useCache = true could possible be set this early in the request flow as the only thing I can see that sets it is a successful call to Mage_Core_Model_Config::loadModulesCache, which if you look at your stack trace is obviously returning false :/

https://github.com/convenient/magento-ce-ee-config-corruption-bug My 100 router fix as discussed in this write the above is all based around the fact that generating the config with useCache = true is a real killer. So, I'd pop this into your Magento instance to make absolutely sure that useCache = false for this bit of code.

Mage_Core_Model_App.php

protected function _initModules()
{
    if (!$this->_config->loadModulesCache()) {
        // Hacks start here!
        $this->_config->setUseCache(false);
        // Hacks end here!
        $this->_config->loadModules();
        if ($this->_config->isLocalConfigLoaded() && !$this->_shouldSkipProcessModulesUpdates()) {
            Varien_Profiler::start('mage::app::init::apply_db_schema_updates');
            Mage_Core_Model_Resource_Setup::applyAllUpdates();
            Varien_Profiler::stop('mage::app::init::apply_db_schema_updates');
        }
        $this->_config->loadDb();
        $this->_config->saveCache();
    }
    return $this;
}

Mage_Core_Model_Config.php

public function setUseCache($bool)
{
    $this->_useCache = (bool) $bool;
}